THREE-DIMENSIONAL (3D) PRINTING TO FILL A PRE-MADE PART
In an example of a three-dimensional (3D) printing method, a pre-made part is positioned. Successive layers of material are applied to fill the pre-made part. A composition of the material is dynamically varied such that a mechanical performance of the material changes from a first portion of the filled pre-made part to a second portion of the filled pre-made part.
In three-dimensional (3D) printing, 3D solid parts may be produced from a digital model using an additive printing process. 3D printing may be used in rapid prototyping, mold generation, mold master generation, and short-run manufacturing. Some 3D-printing techniques are considered additive processes because they involve the application of successive layers of build material. This is unlike traditional machining processes that often remove material to create the final part. In some 3D-printing techniques, the build material may be cured or fused. For some materials, this may be performed using heat-assisted extrusion, melting, or sintering. For other materials, this may be performed using digital light projection technology. Other 3D-printing processes utilize different mechanisms to create 3D shapes, such as printing a binder glue.
Computing devices—such as laptops, notebooks, desktops, tablets, mobile devices, etc.—may be damaged by excessive vibration or by impact with hard surfaces or objects. For example, components such as hard drives may be damaged if a computing device is dropped. In another example, excessive vibration may weaken solder joins on circuit boards or loosen cables or connectors within a computing device.
Computing devices may have external components designed to protect against vibrations and impact. For instance, a laptop or notebook computer may have feet attached to a bottom surface. The material used for the feet may reflect engineering tradeoffs. For example, a hard material may be used to produce a foot that may be durable and wear resistant. A hard material may also result in a foot that has poor energy, vibration, and impact absorption. In another example, a soft material may be used to produce a foot with better isolation and that is energy, shock, vibration, and impact absorbent. A soft material may also result in a foot that is less durable, less wear resistant, and more prone to abrasion.
3D printing is an additive manufacturing process that may be used to manufacture components or parts. In one example, 3D printing may be used to manufacture components for computing devices. This disclosure describes some examples of 3D-printing methods using varied compositions of build materials to manufacture parts that have hard exteriors and soft interiors. These parts may be coupled to devices such that the exterior portion of the part may provide durability and wear-resistance, and the interior portion of the part may provide protection against vibration and impact.
The disclosure further describes the use of pre-made parts to enhance 3D-printed parts. Pre-made parts may be manufactured from build materials that may not be suitable or available for 3D printing. These build materials may exhibit properties, such as strength, hardness, durability, and wear-resistance. In some instances, pre-made parts may exhibit these properties in degrees unavailable from parts manufactured by 3D printing. In addition, pre-made parts may accelerate the 3D-printing process because a portion of the finished part may not need to be 3D printed. Pre-made parts may also decrease the overall cost of the finished part where the pre-made part may be produced at a cost less than that of 3D printing the entire finished part. Pre-made parts may also enable forms or geometries for 3D-printed parts that would be difficult to achieve without the pre-made part.
In the example of
The materials may have different properties. For example, the materials may have different hardnesses and/or strengths. Some examples of materials that may be used include thermoplastic polyurethanes (TPU), which may have many properties, including adjustable hardness and strength with very high abrasion wear, resistance to oil, heat isolation, and excellent low-temperature and impact performance.
The printhead 108 may successively apply and/or deliver build material 106 to fill or grow a 3D part. The printhead 108 may vary the composition of the build material 106 by mixing different proportions of materials 112a-c received from material hoppers 110a-c. In some examples, the printhead 108 may include functionality to mix materials 112a-c to produce the build material 106 for application. In other examples, a separate feeding material system may mix materials 112a-c received from material hoppers 110a-c and provide the build material 106 to the printhead 108.
The printhead 108 may be, for instance, a thermal inkjet printhead, a piezoelectric printhead, etc. In some examples, the printhead 108 may span a width of the working surface 102. Although a single printhead 108 is depicted, multiple printheads 108 may be used that span the width of the working area. Additionally, printheads 108 may be positioned in multiple printbars. The printhead 108 may also be scanned along the x-axis, for instance, in configurations in which the printhead 108 does not span the width of the working surface 102 to enable the printhead 108 to deposit build material 106 over a large area. The printhead 108 may thus be attached to a moving XY stage or a translational carriage (neither of which is shown) that moves the printhead 108 adjacent to the working surface 102 to deposit build material 106 in predetermined areas of a layer and using gradual hardness within the layers. The printhead 108 may include a plurality of nozzles (not shown) through which the build material 106 is extruded.
The controller 116 may be a computing device, a semiconductor-based microprocessor a central processing unit (CPU), an application-specific integrated circuit (ASIC), and/or other hardware device. The controller 116 may be connected to other components of the 3D-printing system 100 via communication lines (not shown).
The controller 116 may control actuators (not shown) to control operations of the components of the 3D-printing system 100. For example, the controller 116 may control actuators that control movement of the printhead 108 along the x-, y-, and/or z-axes. The controller 116 may also control actuators that control the proportions of material 112a-c that are fed into the printhead 108 from each of material hoppers 110a-c. The controller 116 may further control actuators that raise and lower working surface 102 along the z-axis.
The controller 116 may further control actuators to position a pre-made part or mold 104 on working surface 102. The pre-made part 104 may be positioned so that build material 106 may be successively applied to the pre-made part 104. For example, the pre-made part 104 may be positioned such that 3D printing may be performed on the pre-made part 104 to fill or grow the pre-made part 104 through the successive application of build material 106. The pre-made part 104 may form part of the finished 3D part. The pre-made part 104 may be designed with geometry that is consistent with and/or enhances the finished 3D part. Some examples of pre-made parts or molds 104 are shown in
The pre-made part 104 may comprise a single material 112 or a plurality of different materials 112. In one example, the pre-made part or mold 104 may be made of a single material 112. The single material 112 may be a wear-resistant material, such as a thermoplastic polyurethane (TPU). One example of a commercially available TPU material may be COIM LARIPUR® LPR8020 Standard Adipate Ester Polyurethane.
The controller 116 may communicate with a data store 114. The data store 114 may include machine-readable instructions that cause the controller 116 to control the supply of material 112a-c by the material hoppers 110a-c to the printhead 108, control movement of the printhead 108, and control the placement of the pre-made part 104 on the working surface 102.
The data store 114 may be machine-readable storage medium. Machine-readable storage may be any electronic, magnetic, optical, or other physical storage device that stores executable instructions. Thus, machine-readable storage medium may be, for example, Random Access Memory (RAM), an Electrically Erasable Programmable Read-Only Memory (EEPROM), a storage drive, an optical disc, and the like. As described in detail below, machine-readable storage medium may be encoded with executable instructions for controlling 3D-printing system 100.
The data store 114 may include data pertaining to a 3D part to be 3D printed by the 3D-printing system 100. For example, the data store 114 may store data pertaining to the geometry of the 3D part. The date store 114 may further store data pertaining to the proportions of materials 112a-c from each of material hoppers 110a-c to be used to produce the build material 106 for each layer and/or each voxel of the 3D part.
In one example, the controller 116 may communicate with a data store 114 to control actuators that control the components of the 3D-printing system 100 to 3D print or manufacture a 3D part. The controller 116 may control actuators to cause a pre-made part 104 to be positioned at a desired location on working surface 102. The controller 116 may further control actuators to cause the printhead 108 to apply successive layers of build material 106 to the pre-made part 104 to fill or grow the pre-made part 104.
The controller 116 may further control the printhead 108 and material hoppers 110a-c to dynamically vary the composition of the build material 106 by causing materials 112a-c to be mixed in different proportions. In an example, the controller 116 may cause the composition of the build material 106 to be dynamically varied such that a mechanical performance of the build material 106 may change from a first portion of the filled pre-made part to a second portion of the filled pre-made part. For instance, the hardness of the build material 106 may decrease (e.g., from hard 120 to soft 118) and an energy-absorption capability of the build material 106 may increase from the first portion of the filled pre-made part to the second portion of the filled pre-made part. Thus, the build material 106 may comprise a plurality of materials 112a-c and the composition of the build material 106 may be dynamically varied by changing proportions of the materials 112a-c.
The controller 116 may cause the composition of the build material 106 to be dynamically varied to achieve a variety of gradient structures. In one example, the first portion may be a surface of the filled pre-made part, and the second portion may be a center of the filled pre-made part. In other examples, the first and the second portions may be a surface, a center, an internal location, a side, an edge, a corner, etc. of the filled pre-made part. For instance, the composition of the build material 106 may be dynamically varied to achieve a side-to-side gradient, an edge-to-edge gradient, a corner-to-corner gradient, a side-to-center gradient, an edge-to-corner gradient, an internal-location-to-surface gradient, etc.
In one example, a hardness of the build material 106 may decrease (e.g., from hard 120 to soft 118) and an energy-absorption capability of the build material 106 may increase from the first portion of the filled pre-made part to the second portion of the filled pre-made part. The build material 106 may comprise a plurality of materials 112a-c. The 3D-printing system 100 may dynamically vary the composition of the build material 106 by changing proportions of the materials 112a-c.
In an example, the materials 112a-c may comprise a powder and a liquid. The materials 112a-c may be dissimilar. For instance, materials 112a-c may have different hardness and/or strength. Mixing materials 112a-c in different proportions may enable the manufacture of near net-shape 3D parts according to functional needs, such as having a wear-resistant exterior and an energy-absorbing interior. The pre-made part 104 may be manufactured from a material that provides additional wear-resistance to the 3D-printed part. For example, the pre-made part 104 may comprise a thermoplastic polyurethane.
In an example, a composition of the build material 306 may vary such that a mechanical performance of the build material 306 may change from a first portion of the filled mold to a second portion of the filled mold. For instance, a wear resistance of the build material 306 may decrease (e.g., from hard 320 to soft 318) and a vibration-absorption capability of the build material 306 may increase from the first portion of the filled mold to the second portion of the filled mold.
In one example, the first portion may be a surface of the filled mold, and the second portion may be a center of the filled mold. In other examples, the first and the second portions may be a surface, a center, an internal location, a side, an edge, a corner, etc. of the filled mold. The mold 304 may comprise a wear-resistant material. This may enable an exterior portion of the foot 332 to provide durability and wear-resistance, and the interior portion of the foot 332 to provide protection against vibration and impact
In an example, the build material 406 may vary such that a mechanical performance of the build material 406 changes from a first portion of the filled mold 456 to a second portion of the filled mold 456. For instance, as illustrated in
In an example, the build material 506 may vary such that a mechanical performance of the build material 506 changes from a first portion of the filled mold 564 to a second portion of the filled mold 564. For instance, as illustrated in
In an example, the build material 606 may vary such that a mechanical performance of the build material 606 changes from a first portion of the filled mold 666 to a second portion of the filled mold 666. For instance, as illustrated in
In an example, the build material 706 may vary such that a mechanical performance of the build material 706 changes from a first portion of the filled mold 776 to a second portion of the filled mold 776. For instance, as illustrated in
Claims
1. A three-dimensional (3D)-printing method, comprising:
- positioning a pre-made part; and
- applying successive layers of build material to fill the pre-made part, wherein a composition of the build material is dynamically varied such that a mechanical performance of the build material changes from a first portion of the filled pre-made part to a second portion of the filled pre-made part.
2. The 3D-printing method of claim 1, wherein a hardness of the build material decreases and an energy-absorption capability of the build material increases from the first portion of the filled pre-made part to the second portion of the filled pre-made part.
3. The 3D-printing method of claim 1, wherein the build material comprises a plurality of materials, and wherein the composition of the build material is dynamically varied by changing proportions of the materials.
4. The 3D-printing method of claim 3, wherein the materials comprise a powder and a liquid.
5. The 3D-printing method of claim 1, wherein the pre-made part comprises a thermoplastic polyurethane.
6. A foot, comprising:
- a mold; and
- build material filling the mold, wherein a composition of the build material varies such that a mechanical performance of the build material changes from a first portion of the filled mold to a second portion of the filled mold.
7. The foot of claim 6, wherein the mold comprises a hollow cylinder with a tapered closed end.
8. The foot of claim 6, wherein the mold comprises a tapered hollow cylinder with a closed end, an inner surface of the tapered hollow cylinder comprising a plurality of cylindrical portions in a stepped arrangement.
9. The foot of claim 8, wherein a surface of the closed end comprises a plurality of tapered ring portions in a concentric arrangement.
10. The foot of claim 6, wherein the mold comprises:
- a rectangular beam; and
- a plurality of cylinders coupled to a surface of the rectangular beam in a linear arrangement.
11. The foot of claim 6, wherein the mold comprises a first planar surface, a second planar surface, and a third planar surface; and
- wherein the first planar surface and the third planar surface are angled relative to the second planar surface to form a trough shape.
12. A computing device, comprising:
- a bottom surface; and
- a foot connected to the bottom surface, the foot comprising a mold and build material filling the mold, wherein a composition of the build material varies such that a mechanical performance of the build material changes from a first portion of the filled mold to a second portion of the filled mold.
13. The computing device of claim 12, wherein a wear resistance of the build material decreases and a vibration-absorption capability of the build material increases from the first portion of the filled mold to the second portion of the filled mold.
14. The computing device of claim 12, wherein the mold comprises a wear-resistant material.
Type: Application
Filed: Sep 29, 2017
Publication Date: Aug 6, 2020
Inventors: BOASHENG ZHANG (SPRING, TX), HUI LENG LIM (SPRING, TX), JO TICY LO (SPRING, TX)
Application Number: 16/635,044